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MOLTEN METAL
The manufacture of quality zinc and aluminum die-castings begins with adherence to a defined set of alloy melting, handling and degassing procedures. At Bardane, degassing is achieved when the molten metal passes through a rotary degassing unit prior to its introduction to the die casting machine holding furnace. This eliminates oxides that can be responsible for casting hard spots.
Bardane also employs specialized equipment to check for porosity during the manufacture process.
ZINC AND ALUMINUM CASTING PRODUCTION
Bardane specializes in full dies as well as modular tooling for quick set-up of both short and long runs. Our internal structure allows us to be competitive with off-shore pricing, and also allows us to accommodate any size production runs. Hot chamber machines range from
150 to 500 tons. Cold chamber machines range from
600 to 900 tons.
Bardane manufactures zinc and aluminum castings for a wide variety of markets including high finish decorative, electrical, high-tech electronics, typical component part casting, and pressure tight insert castings.
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To cast pressure tight components, give special considerations to all details of the molding process. Depending on pressure tight requirements, the cost of impregnation can be avoided by following the basic design guidelines of radii, draft, uniform sections, etc. Take particular care not to break the casting skin. The following are also recommended:
- Incorporate a vacuum system into the die design. This need not to be complicated, and will assist in removing gasses from the die surface that could “trap” during injection.
- Pay close attention to fillets and metal savers.
- Avoid heavy sections. Heavy sections promote porosity due to heat concentration.
- Core holes as opposed to machining. Machining aggravates porosity.
- Similarly, avoid the removal of large amounts of stock when machining.
- It is recommended that the die caster pressure test a percentage of the castings. Imperfections not visible by physical inspection do exist. The cost associated with pressure testing is minimal compared to impregnation.
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In certain applications, it is desirable to place an insert into the die and cast the molten metal around it. Inserts are used where demands on the component go beyond the capabilities of the zinc and aluminum alloys.
Where a steel thread is required for strength, for example, an insert can be placed in the appropriate area of the mold and metal diecast around it. The casting now conforms to the requisite engineering needs.
The same applies to heater elements. These can also be inserted, with the casting providing the housing for the element as well as the housing for the liquid to be heated.
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